Apparatus for making wheel covers



G. A. LYON APPARATUS FOR MAKING WHEEL COVERS Original Filed Aug. 13, 1953 March 20, 1962 3 Sheets-Sheet 1 Geozye A/berz Lyon EQWM, WE-f1 E March 1962 G. A. LYON 3,025,815

APPARATUS FOR MAKING WHEEL COVERS Original Filed Aug. 13,1953 3 Sheets-Sheet 2 Geozye A berz Lyon f [Z1775 March 20, 1962 G. A. LYON 3,025,815

APPARATUS FOR MAKING WHEEL COVERS Original Filed Aug. 15, 1955 3 Sheets-Sheet 3 F .4 q ii .IZ 15 ii b4) ii Geog ye Albeff j %mm M.

/ fi Z 7 77E trite rates 3,025,815 Patented Mar. 20, 1962 3,025,815 APPARATUS FOR MAKING WHEEL COVERS George Aibert Lyon, Detroit, Mich, assignor to Lyon Incorporated, Detroit, Mich a corporation of Delaware Original application Aug. 13, 1953, Ser. No. 374,076, now Patent No. 2,972,321, dated Feb. 21, 1961. Divided and this application Dec. 10, 1954, filer. No. 474,550 7 Claims. (Cl. 113-49) The present invention relates to a novel apparatus for making wheel covers of the type adapted to be applied in ornamental and protective covering in relation to the outer sides of vehicle wheels.

The method features of the instant wheel cover construction are also covered in my earlier filed application relating to a method for making wheel covers, Serial No. 374,076, filed August 13, 1953, now Patent Number 2,972,321, from which the present subject matter has been divided with respect to the apparatus for making the instant wheel cover disclosed and claimed herein.

An important object of the present invention is to provide novel apparatus for making wheel covers from sheet metal.

Another object of the invention is to provide novel apparatus for making Wheel covers with integral struck out cover retaining fingers.

In accordance with the general features of this invention, there is provided in an apparatus for making a circular article such as a wheel cover from a sheet metal blank and which cover has an annular series of spaced openings, means for dishing an intermediate section of the blank, means for striking integral spaced tabs from the section to form the openings, and means for progressively bending and working the tabs in overlapped relation with an imperforate portion of the blank adjoining the dished section to form cover retaining fingers backed up by the portion.

Other objects, features and advantages of the present invention will be readily apparent from the following detailed description of a preferred embodiment thereof taken in conjunction with the accompanying drawings in which:

FIGURE 1 is a radial sectional view through a wheel cover after it has been partially completed from sheet metal, taken substantially on the line II of FIGURE 2;

FIGURE 2 is a fragmentary more or less segmental outer face elevational view of the partially completed wheel cover. of FIGURE 1;

FIGURE 3 is a fragmentary radial sectional view through the partially completed wheel cover of FIG- URE 1 and punch and die apparatus for striking out the retaining finger tabs or extensions and at the same time providing air circulation openings through the cover;

FIGURE 4 is a similar fragmentary radial sectional view through the partially formed cover and apparatus for bending the struck-out finger tabs into oblique position;

FIGURE 5 is a similar radial sectional view through the partially formed cover and through apparatus for cold working and shaping the retaining finger tabs or extensions;

FIGURE 6 is a radial sectional view similar to FIG- URE 5 but showing the relationship of the apparatus upon completion of the retaining finger;

FIGURE 7 is a fragmentary top plan view of the core die structure of the apparatus of FIGURES 5 and 6 about which the retaining fingers are cold worked and shaped; and

FIGURE 8 is a fragmentary radial sectional view through the finished wheel cover and a vehicle wheel to which the cover may be applied.

As shown on the drawings:

In making a wheel cover 10 according to the present invention, a sheet metal blank such as stainless steel, brass or the like of suitable alloy to provide the requisite working characteristics and service requirement characteristics, is shaped by any suitable drawing, spinning or combination shaping operations. This provides a circular, partially completed cover 10 as seen in FIGURES 1 and 2 including a central crown portion 11 having an annular generally axially inwardly and radially outwardly sloping side wall 12 merging with a more radially outwardly but nevertheless axially inwardly oblique intermediate portion 13 convergently related on a short radius axially inwardly directed rib-like, axially outwardly opening annular channel juncture 14 with a generally radially and axially outwardly directed outer marginal portion 15 which in the present instance is preferably of concave convex large rib-like shape. At suitable spaced intervals, the intermediate portion 13 is provided with depressed preferably generally keystone shaped areas 17 with the wider or head end portions of the depressions at the radially outer sides thereof and extending across the juncture rib 14. At the convergent sides and radially inner ends, the depressed areas 17 are defined by a generally axially inwardly directed continuous flange 18.

According to the present invention, the depressed areas 17 of the cover blank are struck out to provide retaining fingers for the cover and to provide air circulation openings through the cover. To this end, the cover 10 is placed in a punch and die mechanism 19 (FIGURE 3) comprising a lower female die member 20 having the upper surface thereof contoured complementary to the inner surface of the intermediate and annular outer portions 13 and 15 of the cover to receive the same snugly. Complementary depressions 21 in the upper contoured surface of the female die member 24 receive the flanges 18 defining the respective depressed areas of the cover blank, and punch out openings 22 opening downwardly from the depressions 21 generally coincident with the depressed areas 17.

Cooperative with the outer annular portion of the die member 21 and engageable with the radially outer marginal portion 15 of the cover blank on the die member is a hold down die ring 23 having a lower holding surface complementary to the outer convex surface of the cover marginal portion. After the cover blank has been positioned upon the die member 20, the hold down ring is moved into clamping engagement to the outer annular cover portion 15.

After the cover blank has been clamped in position on the die member 20, a relatively reciprocable ring-shaped member 24 reciprocably guided by the hold down ring 23 is driven toward the clamped cover to punch out the depressed areas 17 of the cover by means of depending respective punches 25 which register with the openings 22 and the female die member 20. For this purpose, the upper edges defining the punch holes 22 at the bottom of the respective depressions 21 provide Shearing edges except at the radially outer sides of the openings 22 which merge smoothly with the contoured convex surface complementary to and supporting the outer marginal portion 15 of the cover member. A clearance equal to approximate thickness of the material is afforded between the radially outer face of the respective punches 25 and the radially outer surfaces defining the respective openings 22. Accordingly, as the punches 25 are driven down into the openings 22, the depressed areas 17 of the cover blank are struck out and severed from the flange 18 but remain continuous in one piece as axially inwardly directed extensions from the inner margin of the radially outer portion 15 of the cover. By having the tip portions of the punches 25 provided with a nose contoured complementary to the radius of the juncture groove 14 in that portion of the punch that drives down into the groove, as shown at 27, a smooth working rounded shoulder is provided which acts upon the punched out tongue-like extension 17 to work the same from the oblique radially inwardly and axially outwardly directed position thereof in the unsevered condition into the axially inwardly elongated condition thereof at the completion of the punching and straightening stroke of the punch die member 24. It will be observed that the length of the punch member 25 is preferably as long as the elongated tongue or finger 17 at completion of the axial elongation thereof.

After removal of the cover member 10 from the die assembly 19, it is placed into and worked upon in a die assembly 28 wherein the finger extension tongues or tabs 17 are further engaged and bent toward final shape. To this end, the die assembly 28 comprises a base member 29 of preferably annular shape upon which the cover member 10 is placed in inverted position with the outer surfaces of the intermediate cover portion 13 and the outer annular portion 15 engaging complementary annular upper surfaces of the lower member 29. An annular upper shaping ring 30 is then driven toward the lower supporting ring 29 so that an oblique generally axially and radially inwardly directed working surface 31 thereof will engage and progressively bend the finger tab extensions 17 into oblique generally radially outward directions as viewed in FIGURE 4.

After release from the die assembly 28, the cover member 10 is placed into a final finger tab forming die assembly 32 (FIGURES and 6). The latter die mechanism comprises a base member 33 supporting a reciprocable yieldably mounted cover supporting and retaining finger forming die member 34. Coiled compression springs 35 normally urge the die ring 34 upwardly about a central guide boss 37 into engagement with a stop plate 38. Thereby, an upper annular forming and supporting area or ridge or rib 39 on the die ring 34 is normally supported by the springs 35 in a position to receive the cover member adjacent to juncture of the finger tab extensions 17 with the reinforcing flange 18 and with the distal end portions of the retaining finger extensions 17 clearing a forming rib or forming nose 48 on an upstanding annular portion 41 of the base member 33 disposed in fixed relation at the radially outer side of the die ring 34. It will be observed that the rib 40 has an outer surface area 43 with a portion of the surface area comprising a generally radially outwardly and downwardly axially oblique radially outer surface which is disposed at approximately the same oblique angle as the inner faces of the obliquely disposed finger extensions 17.

Cooperatively related to the forming ridge or rib 40 is a series of circumferentially spaced (FIGURE 7) retaining finger core block elements 44 carried fixedly by an annular ring die member or annulus 45 supported yieldably by compression springs 47 in normally elevated relation above the base member 33 as guided by the annular upstanding portion 41 and with the core elements 44 disposed in spaced relation above the forming ridge or annular nose 40. The member 45 has a ring of circumferentially spaced nose portions or noses 48. In the upwardly extended relation of the member 45, the core elements 44 have the depending nose portions or noses 48 disposed in clearance relation to the radially outer side of the supporting and forming ridge or rib 39 so that the cover 10 can be manipulated into position by extending the radially outwardly angled retaining finger tab extensions 17 into the clearance spaces between the core elements 44 (FIGURE 7) until the outer annular cover portion comes to rest upon the complementary contoured upper faces of the core elements 44. The cover member 10 is then given a turning movement relative to the die structure 32 to register the nose portions 48 of the core members behind the retaining finger tab extensions 17,

the radially inner surface of the nose 48 being complementary in shape, in each instance, to the portion of the retaining finger tab extensions 17 adjacent to juncture thereof with the annular outer cover portion 15 and the reinforcing flange 18.

Then, a clamping and pressure ring 49 is driven into clamping engagement with the upper face of the outer annular cover portion 15 to which it is complementary, to clamp the cover to the core elements 44 as seen in FIG- URE 5. As pressure is thus applied, the proximal portions of the finger extensions 17 are clamped between the nose portions 48 of the core elements and the supporting and forming ridge 39.

Final shaping of the retaining fingers is accomplished by depressing the ring die members 45 and 34 by means of the pressure ring 49 to eifect turning of the distal portions of the finger extensions 17 about the radially oflset complementary forming nose 48 and the core element nose portions 48. To this end, the radially inner side of the forming nose 40 and the radially outer side and tip surfaces of the nose 48 are of complementary shape and obliquely angled generally axially and radially outwardly. Therefore, as the core element nose portions 48 are driven down along side the radially inner side of the nose 40, the retaining finger extensions 17 are turned and each worked progressively into generally axially outwardly and radially outwardly biased or oblique direction as shown in FIGURE 6. In the final phase of the shaping stroke of the die structure, wherein the finger extensions are fully shaped and clamped between the die nose element 48 and the nose 40, the distal terminal extremity portions of the finger extension are bent generally radially outwardly within a reentrant radiused forming surface 50 provided for this purpose at the juncture of the radially outer sides of the forming noses 48 with the body portions of the core elements 44. Thereby the finger extensions 17 are now provided with body portions 17a joining the cover, resilient leg portions 17b angled generally in reverse from the body portions, and short and stiff generally radially outwardly directed cover engaging terminal flanges 170. It will be observed that through appropriate shaping of the dies, the clip of finger body portions 17a, at least are transversely bowed and thus stiffened. Because of the original keystone shape of the finger tabs, the fingers 17 are tapered from their proximal to their distal ends.

Following the finger shaping operation, the die assembly 32 is opened by retracting the pressure ring 49 away from the cover so that the springs 35 and 47 can lift the die rings 34 and 45, respectively, to clear the formed fingers above the forming ridge 40. Then the cover is given sufficient turning movement to clear the formed retaining fingers 17 from the core members 44 and the cover is lifted away from the lower die mechanism of the die assembly 32.

As a final cover shaping operation, the extremity edge portion of the outer annular cover section 15 is preferably turned under to provide a reinforcing and finishing flange 51 (FIGURE 8). At this time, also, further finishing of the cover may be accomplished if desired, al-' though it will be be appreciated that where the cover is to be polished or plated and polished or burnished, that is best accomplished after shaping of the cover as shown in FIGURE 1 and before the finger extensions are punched therefrom and shaped.

The finished cover is adapted to be applied to a vehicle wheel such as shown in FIGURE 8 including a disk Wheel body or spider 52 joined to a multi-fiange tire rim 53 and providing at juncture with the tire rim a plurality of wheel openings 54 through which air may circulate in the operation of the wheel for cooling a brake drum (not shown) of the vehicle axle to which the wheel may be attached. The tire rim includes an outer side flange 55, an intermediate generally radially and axially outwardly oblique flange 57 and a terminal flange 58, the flanges being related to support a pneumatic tire and tube assembly 59.

The retaining fingers 17 engage the tire rim for retaining the cover on the wheel. To this end, the cover is adapted to be pressed axially inwardly so that the retaining finger tips 170 cam into retaining gripping engagement with the inner face of the intermediate flange 57 and stress the finger portion 17b radially inwardly to afford radially outward thrusting pressure for the retaining tips of the finger terminals 170 against the intermediate flange of the tire rim. In the final assembled relation of the cover the shoulder at juncture of the body and flexible finger portions of the fingers 17 engages at the juncture groove between the side flange 55 and the intermediate flange 57, thereby retaining the cover in spaced relation to the wheel body and tire rim portions of the wheel and holding the cover centered on the wheel. Since the outer portion as well as the turned edge portion 51 of the cover is held spaced from the tire rim, air circulation may proceed between the tire rim and such outer portion. Furthermore, the openings defined within the reinforcing flange 18 where the retaining fingers have been struck from the cover afford circulation openings generally registering with or opposite the wheel openings 54.

In view of the foregoing it will now be appreciated that an apparatus for forming a series of circumferentially spaced tongues 17 on an intermediate cover area into circumferentially spaced cover retaining extensions 17 has been provided. To attain this end, superimposed relatively movable lower and upper die portions 44 and 49 have been provided for grasping the outer margin of the cover with the lower die portion 44 having a downwardly facing folding nose 48 including a generally U- shaped surface area having diverging radially inner holding nose surfaces 48a and radially outer folding nose surfaces 48b. Also provided is a radially inner die portion 34 having a holding surface 39a confronting the radially inner nose surface 48a enabling the cover area immediately adjacent the tongues 17 to be backed-up. A forming nose portion 40 is disposed below said lower die portion 44 and is radially outwardly of said radially inner die portion 34 with the forming nose portion 40 including its radially outer surface area 43 being disposed radially outwardly of the folding nose 48 and the supporting area 39 on the inner die portion 34. The surface area 43 includes radially inner and outer converging forming surfaces 43a and 43b. Springs 35 and 37 permit the lower and inner die portions 44 and 34 to be axially movable together relative to the forming nose portion 40 upon the movement of the upper die portion 49 to enable the tongues 17 to be engaged by the-forming nose portion 40 and folded over the outer surface area 43 of the forming nose portion 40 and over the radially outer nose surface 48b of the folding nose 48. During this operation, the terminal ends 170 of the tongues are reverse bent over the forming nose portion 40 through the coaction of the nose portion 40 with the underneath surface 50. Thus, the lower die portion 44 has its underneath surface 50 cooperable with the radially outer folding nose surface 48b so that as the lower die portion 44 is moved with respect to the forming nose portion 40 the forming nose portion 40 is brought into radially confronting relation with respect to the outer nose surface 48b of the lower die portion and with the forming nose portion 40 axially confronting the underneath surface 50 enabling the tongues 17 to be folded over the converging surfaces 43a and 43b as a consequence of the relative movement between the lower die portion 44 and the forming nose portion 40.

It will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention.

I claim as my invention:

1. In an apparatus for forming a series of circumferentially spaced tongues on an intermediate cover area into circumferentially spaced cover retaining extensions, super-imposed relatively movable upper and lower die portions for grasping the outer margin of the cover with the lower die portion having a series of downwardly facing folding noses each including radially inner and outer nose surfaces, a radially inner die portion having a surface confronting the radially inner nose surface enabling the cover area immediately adjacent the tongues to be backed-up, and a forming nose portion disposed below said lower die portion and radially outwardly of said radially inner die portion with said forming nose portion including radially inner and radially outer forming surfaces, and means permitting the lower and inner die portions to be movable together relative to the forming nose portion upon the movement of the upper die portion whereby the tongues are engaged by the forming nose portion and are folded over the folding noses including their radially outer nose surfaces with the terminal ends of the tongue then being reverse bent over the forming nose portion, the folding noses being disposed radially between the forming nose portion and the radially inner die portion when the tongue is reverse bent.

2. In an apparatus for forming a series of circumferentially spaced tongues on an intermediate cover area into circumferentially spaced cover retaining extensions, super-imposed relatively movable upper and lower die portions for grasping the outer margin of the cover with the lower die portion having a series of downwardly facing folding noses each including radially inner and outer nose surfaces, a radially inner die portion having a surface confronting the radially inner nose surface enabling the cover area immediately adjacent the tongues to be backed-up, and a forming nose portion disposed below said lower die portion and radially outwardly of said radially inner die portion with said forming nose portion including radially inner and radially outer forming surfaces, and means permitting the lower and inner die portions to be movable together relative to the forming nose portion upon the movement of the upper die portion whereby the tongues are engaged by the forming nose portion and are folded over the folding noses including their radially outer nose surfaces with the terminal ends of the tongue then being reverse bent over the forming nose portion, the folding noses being disposed radially between the forming nose portion and the radially inner die portion when the tongue is reverse bent, said lower die portion having an underneath surface cooperable with the forming nose so that as said lower die portion is moved with respect to the forming nose portion, the radially inner forming surface of the forming nose portion is brought into confronting relation with respect to the outside outer nose surface of the lower die portion and with the forming nose portion confronting the underneath surface enabling the tongues to be folded as a consequence of the relative movement, between said lower die portion and said forming nose portion.

3. In apparatus for making a wheel cover, means on said apparatu for supporting a cover member having intermediately struck-out elongated generally axially directed tabs, core elements on said apparatus disposed axially on one side of said means and cooperable therewith in the working of the tabs, the core elements being engageable axially behind the cover member at the juncture of said tabs with the cover member, and forming means on said apparatus disposed axially of said means on the same side as said core elements and being disposed radially of said core elements with the forming means and the core elements being movable axially relative to one another for bending said tabs into generally U- shaped retaining spring fingers.

4. In apparatus for making a wheel cover, means on said apparatus for supporting a cover member having intermediately struck-out elongated generally axially directed tabs, core elements on said apparatus disposed axially on one side of said means and cooperable therewith in the Working of the tabs, the core elements being engageable axially behind the cover member at the juncture of said tabs with the cover member, and forming means on said apparatus disposed axially of said means on the same side as said core elements and being disposed radially of said core elements wtih the forming means and the core elements being movable axially relative to one another for bending said tabs into generally U- shaped retaining spring fingers, said forming means comprising a rib having one side engageable by the terminal portions of the tabs and the other side cooperable with the core members in bending the tabs into U-shape and to afford spring resilience in the thus worked tabs.

5. In apparatus for making a wheel cover, means on said apparatus for supporting a cover member having intermediately struck-out elongated generally axially directed tabs, core elements on said apparatus disposed axially on one side of said means and cooperable therewith in the working of the tabs, the core elements being engageable axially behind the cover member at the juncture of said tabs with the cover member, and forming means on said apparatus disposed axially of said means on the same side as said core elements and being disposed radially of said core elements with the forming means and the core elements being movable axially relative to one another for bending said tabs into generally U-shaped retaining spring fingers, said core elements being carried by a ring with spaces between the core elements into which the tabs are extended initially and the cover member then turned to bring the core members into registration with the tabs.

6. In apparatus for making a Wheel cover, the apparatus having means for supporting a cover member having intermediately struck-out elongated generally axially directed tabs, the apparatus having circumferentially spaced core portions disposed axially on one side of said means and cooperable therewith in the working of the tabs, the core portions being engageable axially behind the cover member at the juncture of the tabs with the cover member, and the apparatus having forming means disposed axially of said means on the same side as said circumferentially spaced core portions and being disposed radially of said core portions with the forming means and the core portions being movable axially relative to one another for bending the tabs into generally U-shaped retaining spring fingers.

7. In an apparatus for forming tabs struck from an intermediate cover area on a wheel cover into retaining extensions, the apparatus including supporting structure for supporting a Wheel cover for backing up the cover margin leaving the struck out tabs unsupported, and means disposed axially of the supporting structure including a series of circumferentially spaced interconnected noses and an annular nose generally axially confronting the circumferentially spaced noses when they are axially spaced, said spaced noses and said annular nose being disposed underneath the marginal supporting structure and being relatively movable axially one with respect to the other and cooperable together, and said annular nose generally radially confronting said circumferentially spaced noses upon relative axial movement for bending said tabs angularly relative to the axis of the cover member to form the tabs into retaining extensions.

References Cited in the file of this patent UNITED STATES PATENTS 307,357 Twedell Oct. 28, 1884 518,766 Plecker Apr. 24, 1894 977,639 Lachman Dec, 6, 1910 985,452 Roediger Feb. 28, 1911 1,044,283 Stanger Nov. 12, 1912 1,749,184 Hansen et al Mar. 4, 1930 1,961,404 Tormyn et al June 5, 1934 2,105,289 Lobdell Jan, 11, 1938 2,240,294 Greif Apr. 29, 1941 FOREIGN PATENTS 471,604 Canada Feb. 20, 1951 

